Method of producing frozen comestibles



A. H. GOODMAN UAL `3',4|75,I8 2" METHOD OF PRODUCING FROZEN COMESTI-BLES Original Filed latch 5, i966 Oct. 28, 1969 2 Sheets-Sheet l Oct. 28, 1969 Original Filed March 3, 1966 A. H. GOODMAN UAL 3,475;182`

METHOD 0F PRODUCING FROZEN GOMESTIBLES 2 Sheets-Sheet 2 Arran/ys United States Patent O Int. c1. Azsg 5/00 U.s. Cl. 99-136 11 Claims ABSTRACT OF THE DISCLSURE Producing a frozen comestible by forming a first fraction of ythe comestible and water into a liquid mix, pasteurizing, homogenizing and precooling the mix. Thereafter, pumping the mix through an ice cream freezer and injecting air into the mix to produce an overrun, injecting a particulate second fraction including prebaked farinaceous material into the mix and owing the mix through mixer to an extruder which shapes the product, and subsequently freeze-solidifying.

This is a continuation of patent application Ser. No. 530,776, filed Mar. 3, 1966, now Patent No. 3,378,378, for Frozen Comestible and Method of Producing Same.

The present invention relates generally to improvements in comestibles and it relates in particular to an improved method for the production of a frozen comestible of the nature of an ice cream and cake product or ice milk and cake product or Mellorine and cake product.

In the production of ice cream cakes by procedures generally practiced heretofore, the cake is produced at a bakery by the conventional methods in the desired shape, commonly as at sheets and is then packaged and shipped to the ice cream plant, where the ice cream is produced in a semi-frozen lluid state and applied to the cake. The composite product is then frozen and packaged and distributed through the usual channels. The above procedure possesses many drawbacks and disadvantages. The producer of the ice cream cake frequently must rely upon an independent bakery for the regular supply of the cake component in a condition and shape suitable for combining it with the ice cream in the production of the ice cream cake and the conventional cake maintains this suitable condition for only a limited time. Furthermore, combining the cake and ice cream is an expensive and timeconsuming procedure, of little flexibility and adaptability. Thus, the conventional procedure for the production 0f ice cream cake is costly, ineicient and of limited application.

It is, therefore, a principal object of the present invention to provide an improved method for the production of comestibles.

Another object of the present invention is to provide an improved method for the production of frozen comestibles of the nature of ice cream cake and the like.

Still another object of the present invention is to provide an improved method for the production of ice cream cake wherein are obviated the requirement of the preshaped baked cake component and its attendant limitations.

A further object of the present invention is to provide an improved method for the production of ice cream cake wherein only conventional ice cream producing equipment is required.

Still a further object of the present invention is to provide an improved method of the above nature character- ICC ized by its efliciency, economy and flexibility and the adaptability, high quality and low cost of the end product.

The above and other objects of the present invention will become apparent from a reading of the following de| scription taken in conjunction with the accompanying drawing, wherein FIGURE 2 is a graph in which the delineated area covers the ranges of proportions of ingredients of `the present comestible; and FIGURE l is a flow diagram illustrating a preferred procedure in accordance with the present invention for producing the improved comestible.

ln a sense, the present invention contemplates the provision of a frozen comestible comprising a matrix formed of between 35% and 50% by weight of said comestible of water, and between 30% and 50% by dry weight of said comestible of a normally solid first fraction of a material at least suspended in said water, and a second fraction of a. relatively coarse particulate edible material dispersed through and supported by said matrix and constituting 10% to 30% by dry weight of said comestible, a major part of said second fraction being a baked farinaceous product, containing between 50% and 65% by dry Weight of non-aqueous solids. Another feature of the present invention resides in the method of producing the improved frozen comestible which comprises admixing the first fraction with water and cooling the mixture to form a viscous flowable mass and thereafter dispersing the second fraction in the flowable mass and freezing the mixture to a solid state.

The parameters set forth are delineated by the area in the graph of FIGURE 2, all percentages being based on dry weight of the total weight of the comestible.

The novel frozen comestible is of the nature of a frozen cake and may have the texture, appearance and palatability of conventional frozen baked cake or may be widely modified in these properties and possesses many advantages over the conventional ice cream cake in that it is more convenient and eflicient to produce, is susceptible to the production of a greater variety of products and is of overall superior quality. It has been discovered that in order to obtain a product of the aforesaid nature the ranges of water and dry ingredients and the proportions thereof forming the matrix and in a relatively coarse particulate state dispersed in the matrix are critical.

The materials of the first fraction are either watersoluble or are suspendible in water and advantageously comprise for the most part milk solids, sugars and fats, aside from or as contained in the milk solids, and in addition preferably contains other ingredients such as stabilizers, emulsiers, sequestering agents, flavors, coloring and the like. The materials of the second fraction is in at least a major part of a prebaked product and advantageously is primarily of a particle size between 2 and 30 mesh and may be crushed cookies, cake in a dried state which is particulated in any suitable manner, or the like.

The rst fraction is homogeneously admixed with the water and cooled advantageously to a temperature of 19 F. to 29 F. to a uid semisolid state to form the matrix, advantageously, though not necessarily, with an overrun. Conventional ice cream producing equipment may be employed to great advantage in this mixing. The second fraction is then admixed with the fluid matrix and the mixture thereafter frozen to a solid state, the second fraction being dispersed in and supported by the solid matrix. The mixture of the matrix and the second fraction while in a fluid state is extruded or otherwise formed to any desired shape before it is freeze hardened, either alone or with ice cream or the like which may be concurrently and continuously produced and combined with the Huid mixture in any desired arrangement. The second fraction may be admixed with the aqueous matrix composition before the cooling of 3 the latter and the mixture then freeze hardened. In the latter procedure, the baked farinaceous material is advantageously coated with a thin layer of fat or other water protective material.

The material of the rst fraction which forms a support matrix with the water is at least suspendible in the water, that is, it is water-soluble or is so finely divided or of such a nature as to form a suspension therein. Advantageously between 7% and 28% by weight of the first fraction are non-fat milk solids and the like and between 10% and 30% are one or more sugars. In addition, the rst material preferably contains fat, a stabilizer, an emulsier, a sequestering agent if desired and a avoring. The following are the preferred ranges of percentages on the weight of the matrix of the ingredients of the first fraction solids material by dry weight.

While the fat is advantageously butter fat, it may be substituted in whole or in part by a suitable vegetable or animal fat-such as Mellorine, or the like. The non-fat milk solids may be dried milk or dried non-fat milk as such, milk or skim milk as such, buttermilk whole or solid, or whey, calculated on the solids content thereof with the water calculated as part of the water phase of the present composition, or similarly, evaporated milk, or condensed sweet cream, buttermilk and combinations thereof and the like, and may include as a part thereof caseinates, for example, casein prepared by precipitation with gums, ammonium caseinate, sodium caseinateI and calcium caseinate. The sugar may be, for example, sucrose, dextrose, corn syrup, invert sugar, various sweet syrups, lactose, fructose, maltose, and the like and combinations thereof.

The stabilizer may be a natural or artificial gum, for example, agar-agar, algin, gelatin, guar seed gum, gum acacia, gum tragacanth, Irish moss, pectin, propylene glycol, alginate, sodium carboxymethylcellulose and the like. As an emulsifier there may be employed theI monoglycerides or diglycerides or both of fat forming fatty acids or the polyoxyethylene emulsifiers such as Tween 65 and Tween 80. The sequestering agent is advantageously tetrasodium pyrophosphate.

The miscellaneous additives may include one or more natural or artificial colors and avors, for example, chocolate, cocoa, ground spices, coffee, vanilla, fruit, fruit extracts and juices, nut meats, marshmallow, candy confections, crunches and the like.

The matrix advantageously, but not necessarily, contains an overrun, that s, injected air which increases the volume of the matrix. The overrun is advantageously u p to 100% and preferably between 30% and 70%, that is, the volume of the matrix is increased in volume or expanded by the overrun percentage based on the unexpanded volume of the matrix. The air is injected following the mixing of the dry ingredients with the water and the homogenization thereof and during the cooling of the matrix to form a tlowable viscous mass and prior to the addition of the coarse second fraction material.

The second fraction is a relatively coarse particulate material comprising in at least a major part thereof a baker farinaceous material of low moisture content and wherein a major part of the material is of a particle size between 2 mesh and 30 mesh, advantageously not more than 10% thereof being coarser than 2 mesh and not more than 30% thereof being finer than 30 mesh. The baked farinaceous material of the second fraction advantageously has a moisture content in its premixed state 4 of between 1% and 15% based on the weight thereof and preferably between 5% and 8% The material of the second fraction may be, for example, any crushed cake or cookie or other baked farinaceous product having a moisture content not exceeding 15 and the particle size above set forth. The bulk density or specific gravity of the second fraction material advantageously does not exceed 0.80 and is preferably between 0.25 and 0.40. The preferred composition of the baked farinaceous portion of the second fraction material or the body thereof is- In addition to the above, the baked farinaceous second fraction material may contain up to 15 of the weight thereof of other additives such as flavors, for example, cocoa, chocolate, salt, spices, vanilla, dried fruits, nuts and the like, coloring, etc. Up to 50% of the second fraction may include coarse particulate fruits, nuts, coconut meat, marshmallow, chocolate chips, confection chips or other particulate edible material.

In preparing the improved frozen comestible according to a preferred procedure of the present invention, the first solids fraction is admixed with the water to effect the solution of the water-soluble portion thereof and the dispersion of the water-insoluble portion in the water, and the resulting mixture is then advantageously homogenized to produce a uniform product with the insolubles substantially in aqueous suspension. Thereafter, the mixture is cooled to a temperature between 19 F. and 26 F. to a matrix-defining viscous flowable mass with the injection of air therein to produce the desired overrun, preferably between 30% and 70%. The second fraction is then added and uniformly dispersed in the matrix and the resulting mixture shaped and frozen to effect the solidication thereof.

Conventional ice cream producing equipment may be employed in the present process which may be of a batch or continuous nature. The final freeze hardening step may be preceded by the extrusion or other forming of the product into any desired shape or may form, for example, a sheet, and this may be packaged as such or combined with other similar or different comestible sheets which may likewise Ibe concurrently extruded or may be formed into stickless as well as stick-supported novelty products in various combinations.

Referring now to FIGURE 1 of the drawings which illustrates a preferred form of the present procedure for producing the present product packaged in alternate layers with ice cream or other extrudable material, conventional ice cream producing equipment being employed throughout, reference numeral 10 generally designates a mixer into which is metered or batch fed the first fraction and water in the desired matrix proportions. The mixing is effected so as to dissolve the water soluble portion of the rst fraction and uniformly disperse the remainder thereof to produce a uniform mixture in the mixer 10. The liquid mix ows from mixer 10 through any suitable pasteurizer 11 to a continuous homogenizer 12 of conventional type, the homogenized pasteuri'zed liquid passing through a precooler 13 where its temperature is reduced to 36 F. to 42 F., into a cool storage tank 14.

The cooled liquid matrix is pumped from tank 14 through any conventional continuous ice cream freezing device 16 where air is preferably injected and entrapped therein to produce an overrun of preferably 30% to 70% and it is cooled to a temperature of preferably between 19 F. and 26 F. in which state it is a viscous tlowable homogeneous mass. A metering injector 17 of known construction feeds the particulate second fraction into the cooled matrix at a predetermined rate and the cooled matrix and the second fraction material carried thereby ilow through a mixer 18, preferably of the in-line type, to lany suitable shaping device such as an extruder 19. The shaped product is then freeze-solidified either as such, in packaged form alone, or with one or more alternating layers of ice cream or the like which may be concurrently shaped therewith. The freeze solid temperature of the end product is preferably below 0 F.

The following are examples of the first fraction which may be employed to advantage, given in percent by weight of the matrix, the remainder of the matrix, by percent by weight of water being admixed therewith to form the matrix:

EXAMPLE I Percent Butterfat 12 Non-fat milk solids 11.5 Sugar r 23 Cocoa solids 3.5 Stabilizer 0.4 Emulsifier 0.1

EXAMPLE II Butterfat 10 Non-fat milk solids 12 Sugar 24 Cocoa solids 3 Stabilizer 0.4 Emulsifier 0.1

EXAMPLE III Butterfat 5 Non-fat milk solids 13 Sugar 25 Cocoa solids 4 Stabilizer 0.4 Emulsilier 0.1

EXAMPLE IV Fats 0 Non-fat milk solids 15 Sugar 27 Cocoa solids 4 Stabilizer 0.4 Emulsilier 0.1

EXAMPLE V Mellorine 10 Non-fat milk solids 12 Sugar 24 Cocoa solids 3 Stabilizer 0.4 Emulsier 0.1

EXAMPLE VI Butterfat 12 Non-fat milk solids 13 Sodium caseinate 1 Sugar 23 Stabilizer 0.4 Emulsier 0.1 Flavor To taste EXAMPLE VII Butterfat 12 Non-fat milk solids 13 Sugar 23 Strawberry 6 Stabilizer 0.4 Emulsilier 0.1

6 EXAMPLE VIII Percent Butterfat 12 Non-fat milk solids 13 Sodium caseinate 1 Sugar 23 Banana l0 Stabilizer 0.4 Emulsifier 0.1

EXAMPLE IX Butterfat 10 Non-fat milk solids 14 Sugar 25 Orange 3 Lemon 2 Stabilizer 0.4 Emulsilier 0.1

EXAMPLE X Butterfat 14 Non-fat milk solids 11 Sugar 25 Cocoa solids 5 Stabilizer 0.4 Emulsier 0.1

In the above examples, although the stabilizer is advantageously sodium carboxymethylcellulose and the emulsifier a monoglyceride or diglyceride of a fat forming fatty acid, other stabilizers and emulsiiers may be employed. Moreover, where fruits are employed as liavoring these should be in a relatively finely divided state.

The second fraction is advantageously a cookie or cake produced in accordance with conventional baking practices, having a moisture content not exceeding 15%, preferably between 5% and 8% comminuted or crushed to a particle size and having a bulk density as earlier set forth. The particulate second fraction may be admixed with any of the above matrices in the manner described and within the range of proportions above set forth. For example, 30 parts of a high shortening containing particulated cookie may advantageously be admixed with parts of the matrix of Example IV, 30 parts of a medium rich shortening particulated chocolate cookie may be advantageously admixed with 100 parts of the matrix of Example III, 26 parts of particulated cookie may be admixed with the matrix of Example I, 28 parts of particulated chocolate cookie may be admixed with the matrix of Example II, 23 parts of particulated chocolate cookie may be admixed with the matrix of Example V, 22 parts of a particulated orange lemon cake may advantageously be admixed with 100 parts of the matrix of Example IX and 15 parts of particulate cookie may be mixed with the matrix of Example X.

While there have been described preferred embodiments of the present invention it is apparent that numerous alterations, omissions and additions may be made without departing from the spirit thereof.

What we claim is:

1. A method of producing a frozen comestible, the comestible comprising an aqueous admixture of a irst fraction and a second fraction, said admixture containing between 50% and 65% by weight of solids and the balance Water, said first fraction including at least milk solids and a sweetening agent and constituting between 30% and 50% by dry weight of said admixture, said second fraction including a relatively coarse particulate edible material constituting between 10% and 20% by dry weight of said admixture, a major portion of said second fraction being a prebaked farinaceous cake-like product, said prebaked farinaceous product constituting at least 10% dry weight of said admixture, the method comprising the steps of:

(a) homogeneously admixing the rst fraction and water,

(b) cooling the admixture to a viscous flowable state,

then

(c) dispersing the second fraction in the admixture,

then

(d) freezing the admixture to a substantially solid state.

2. A method of producing a frozen comestible according to claim 1, wherein in step (b) the admixture is cooled to a temperature of ybetween 19 F. and 29 F.

3. A method of producing a frozen comestible according to claim 1, wherein the admixture prior to step (d) is injected with a gas to increase the volume thereof up to 100% of the unexpanded volume thereof.

4. A method of producing a frozen comestible according to claim 3, wherein the admixture during step (b) is injected with air to increase the volume thereof between 30% and 70% of the unexpanded volume thereof.

5. A method of producing a frozen comestible according to claim 1, wherein the admixture is formed to a predetermined shape immediately prior to step (d).

6. A method of producing a frozen comestible according to claim 5, wherein the admixture is alternately layered with ice cream prior to step (d).

7. A method of producing a frozen comestible according to claim 1, wherein the first fraction includes between 7% and 28% of non-fat milk solids, between 10% and 30% of sugar, up to 16% of fat, a stabilizer, an emulsifier and up to 15% of an additive.

8. A method of producing a frozen comestible according to claim 1, further including the step of homogenizing the admixture prior to step (b).

9. A method of producing a frozen comestible, the comestible comprising an aqueous admixture of a iirst fraction and a second fraction, said admixture containing between 50% and 65% by weight of solids and the balance water, said rst fraction including at least milk solids and a sweetening agent and constituting between 30% and 50% by dry weight of said admixture, said second fraction including a relatively coarse particulate edible mal terial constituting between 10% and 20% by dry weight of said admixture, a major portion of said second fraction being a prebaked farinaceous cake-like product, said prebaked farinaceous product constituting at least 10% by dry weight of said admixture, the method comprising the steps of:

(a) homogeneously admixing the first fraction and water,

(b) dispersing the second fraction in the admixture,

then

(c) freezing the admixture to a substantially solid state.

10. A method of producing a frozen comestible according to claim 9, further including the steps of coating the farinaceous cake-like product with a thin layer of a water protective material.

11. A method of producing a frozen comestible, the comestible comprising an aqueous admixture of a rst fraction and a second fraction, said admixture containing `between 5 0% and 65 by weight of solids and the balance water, said rst fraction including at least milk solids and a sweetening agent and constituting between 30% and by dry weight of said admixture, said second fraction including a relatively coarse particulate edible material constituting between 10% and 20% by dry weight of said admixture, a major portion of said second fraction being a prebaked farinaceous cake-like product, said prebaked farinaceous product constituting at least 10% by dry weight of said admixture, the method comprising the steps of:

(a) admixing the first fraction and water to dissolve and disperse the rst fraction in the water, (b) pasteurizing the admixture, (c) homogenizing the admixture, (d) cooling the admixture to a viscous flowable state having a temperature range of from 36 F. to 42 F.

(e) injecting the admixture with air to increase the volume thereof between 30% and 70% of the unexpanded volume of the admixture,

(f) injecting the second fraction into the admixture,

then

(g) mixing the admixture in an in-line mixer,

(h) shaping the admixture in an extruder, and

(i) freezing the admixture to a substantially solid state.

References Cited UNITED STATES PATENTS 3,378,378 4/1968 Goodman et al. 99--136 A. LOUIS MONACELL, Primary Examiner I M. HUNTER, Assistant Examiner U.S. Cl. X.R. 99-137 

